U.S. patent application number 15/620280 was filed with the patent office on 2017-12-21 for method of manufacturing semiconductor device, substrate processing apparatus, and recording medium.
This patent application is currently assigned to HITACHI KOKUSAI ELECTRIC INC.. The applicant listed for this patent is HITACHI KOKUSAI ELECTRIC INC.. Invention is credited to Yoshitomo HASHIMOTO, Yoshiro HIROSE, Ryota HORIIKE, Hajime KARASAWA, Naoharu NAKAISO, Satoshi SHIMAMOTO.
Application Number | 20170365467 15/620280 |
Document ID | / |
Family ID | 60660855 |
Filed Date | 2017-12-21 |
United States Patent
Application |
20170365467 |
Kind Code |
A1 |
SHIMAMOTO; Satoshi ; et
al. |
December 21, 2017 |
METHOD OF MANUFACTURING SEMICONDUCTOR DEVICE, SUBSTRATE PROCESSING
APPARATUS, AND RECORDING MEDIUM
Abstract
There is provided a method of manufacturing a semiconductor
device, which includes: forming a first seed layer containing
silicon and germanium on a substrate by performing, a predetermined
number of times, a cycle which includes supplying a first process
gas containing silicon or germanium and containing a halogen
element to the substrate, supplying a second process gas containing
silicon and not containing a halogen element to the substrate, and
supplying a third process gas containing germanium and not
containing a halogen element to the substrate; and forming a
germanium-containing film on the first seed layer by supplying a
fourth process gas containing germanium and not containing a
halogen element to the substrate.
Inventors: |
SHIMAMOTO; Satoshi;
(Toyama-shi, JP) ; HIROSE; Yoshiro; (Toyama-shi,
JP) ; KARASAWA; Hajime; (Toyama-shi, JP) ;
HORIIKE; Ryota; (Toyama-shi, JP) ; NAKAISO;
Naoharu; (Toyama-shi, JP) ; HASHIMOTO; Yoshitomo;
(Toyama-shi, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
HITACHI KOKUSAI ELECTRIC INC. |
Tokyo |
|
JP |
|
|
Assignee: |
HITACHI KOKUSAI ELECTRIC
INC.
Tokyo
JP
|
Family ID: |
60660855 |
Appl. No.: |
15/620280 |
Filed: |
June 12, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C23C 16/45546 20130101;
C23C 16/0272 20130101; C23C 16/28 20130101; C23C 16/45544 20130101;
H01L 21/02381 20130101; C23C 16/45527 20130101; H01L 21/02532
20130101; C23C 16/52 20130101; H01L 21/0262 20130101; H01L 21/0245
20130101; H01L 21/02645 20130101 |
International
Class: |
H01L 21/02 20060101
H01L021/02; C23C 16/52 20060101 C23C016/52; C23C 16/455 20060101
C23C016/455 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 15, 2016 |
JP |
2016-118468 |
Claims
1. A method of manufacturing a semiconductor device, comprising:
forming a first seed layer containing silicon and germanium on a
substrate by performing, a predetermined number of times, a first
cycle which includes supplying a first process gas containing
silicon or germanium and containing a halogen element to the
substrate, supplying a second process gas containing silicon and
not containing a halogen element to the substrate, and supplying a
third process gas containing germanium and not containing a halogen
element to the substrate; and forming a germanium-containing film
on the first seed layer by supplying a fourth process gas
containing germanium and not containing a halogen element to the
substrate.
2. The method of claim 1, wherein the first cycle includes
performing the act of supplying the first process gas, the act of
supplying the second process gas and the act of supplying the third
process gas in this order.
3. The method of claim 1, wherein the first cycle includes
performing the act of supplying the first process gas, the act of
supplying the third process gas and the act of supplying the second
process gas in this order.
4. The method of claim 1, wherein the first cycle includes
alternately performing the act of supplying the first process gas
and an act of simultaneously performing the act of supplying the
second process gas and the act of supplying the third process
gas.
5. The method of claim 1, further comprising: forming a second seed
layer containing silicon on the substrate by performing, a
predetermined number of times, a second cycle which includes the
act of supplying the first process gas and the act of supplying the
second process gas, wherein the act of forming the second seed
layer and the act of forming the first seed layer are performed
before performing the act of forming the germanium-containing
film.
6. The method of claim 5, wherein the second cycle includes
alternately performing the act of supplying the first process gas
and the act of supplying the second process gas.
7. The method of claim 1, further comprising: forming a third seed
layer containing germanium on the first seed layer by performing, a
predetermined number of times, a third cycle which includes the act
of supplying the first process gas and the act of supplying the
third process gas, wherein the act of forming the third seed layer
is performed after performing the act of forming the first seed
layer and before performing the act of forming the
germanium-containing film.
8. The method of claim 7, wherein the third cycle includes
alternately performing the act of supplying the first process gas
and the act of supplying the third process gas.
9. The method of claim 5, wherein before performing the act of
forming the germanium-containing film, alternately repeating the
act of forming the second seed layer and the act of forming the
first seed layer is performed, in a former-half period of an
execution period of the act of alternately repeating, a number of
execution times of the second cycle is made larger than a number of
execution times of the first cycle, and in a latter-half period of
the execution period of the act of alternately repeating, the
number of execution times of the first cycle is made larger than
the number of execution times of the second cycle.
10. The method of claim 1, further comprising: forming a first cap
layer containing silicon and germanium on the germanium-containing
film by performing, a predetermined number of times, a fourth cycle
which includes the act of supplying the first process gas, the act
of supplying the second process gas and the act of supplying the
third process gas.
11. The method of claim 10, further comprising: forming a second
cap layer containing silicon on the first cap layer by performing,
a predetermined number of times, a fifth cycle which includes the
act of supplying the first process gas and the act of supplying the
second process gas.
12. The method of claim 11, wherein after performing the act of
forming the germanium-containing film, alternately repeating the
act of forming the first cap layer and the act of forming the
second cap layer is performed, in a former-half period of an
execution period of the act of alternately repeating, a number of
execution times of the fourth cycle is made larger than a number of
execution times of the fifth cycle, and in a latter-half period of
an execution period of the act of alternately repeating, the number
of execution times of the fifth cycle is made larger than the
number of execution times of the fourth cycle.
13. The method of claim 1, wherein the fourth process gas has the
same molecular structure as the third process gas.
14. A substrate processing apparatus, comprising: a process chamber
in which a substrate is accommodated; a supply system configured to
supply a first process gas containing silicon or germanium and
containing a halogen element, a second process gas containing
silicon and not containing a halogen element, a third process gas
containing germanium and not containing a halogen element and a
fourth process gas containing germanium and not containing a
halogen element to the substrate accommodated in the process
chamber; and a controller configured to control the supply system
to perform inside the process chamber: forming a first seed layer
containing silicon and germanium on the substrate by performing, a
predetermined number of times, a cycle which includes supplying the
first process gas to the substrate, supplying the second process
gas to the substrate, and supplying the third process gas to the
substrate; and forming a germanium-containing film on the first
seed layer by supplying the fourth process gas to the
substrate.
15. A non-transitory computer-readable recording medium storing a
program that causes a computer to control a substrate processing
apparatus so as to perform: forming a first seed layer containing
silicon and germanium on a substrate accommodated in a process
chamber of the substrate processing apparatus by performing, a
predetermined number of times, a cycle which includes supplying a
first process gas containing silicon or germanium and containing a
halogen element to the substrate accommodated in the process
chamber, supplying a second process gas containing silicon and not
containing a halogen element to the substrate accommodated in the
process chamber, and supplying a third process gas containing
germanium and not containing a halogen element to the substrate
accommodated in the process chamber; and forming a
germanium-containing film on the first seed layer by supplying a
fourth process gas containing germanium and not containing a
halogen element to the substrate accommodated in the process
chamber.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is based upon and claims the benefit of
priority from Japanese Patent Application No. 2016-118468, filed on
Jun. 15, 2016, the entire contents of which are incorporated herein
by reference.
TECHNICAL FIELD
[0002] The present disclosure relates to a method of manufacturing
a semiconductor device, a substrate processing apparatus, and a
recording medium.
BACKGROUND
[0003] As one of the processes for manufacturing a semiconductor
device, a film forming process of forming a seed layer containing
silicon (Si) on a substrate and subsequently forming a film
containing Si on the seed layer.
[0004] However, if such a film forming technique is used in the
case of forming a film containing germanium (Ge) instead of a film
containing Si, a film quality may deteriorate in some cases.
SUMMARY
[0005] The present disclosure provides some embodiments of a
technique capable of improving a film quality of a film formed on a
substrate.
[0006] According to one embodiment of the present disclosure, there
is provided a method of manufacturing a semiconductor device, which
includes: forming a first seed layer containing silicon and
germanium on a substrate by performing, a predetermined number of
times, a cycle which includes supplying a first process gas
containing silicon or germanium and containing a halogen element to
the substrate, supplying a second process gas containing silicon
and not containing a halogen element to the substrate, and
supplying a third process gas containing germanium and not
containing a halogen element to the substrate; and forming a
germanium-containing film on the first seed layer by supplying a
fourth process gas containing germanium and not containing a
halogen element to the substrate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a schematic configuration diagram of a vertical
type processing furnace of a substrate processing apparatus
suitably used in one embodiment of the present disclosure, in which
a portion of the processing furnace is shown in a vertical cross
sectional view.
[0008] FIG. 2 is a schematic configuration diagram of the vertical
type processing furnace of the substrate processing apparatus
suitably used in one embodiment of the present disclosure, in which
a portion of the processing furnace is shown in a cross sectional
view taken along line A-A in FIG. 1.
[0009] FIG. 3 is a schematic configuration diagram of a controller
of the substrate processing apparatus suitably used in one
embodiment of the present disclosure, in which a control system of
the controller is shown in a block diagram.
[0010] FIG. 4A is a diagram showing a film forming sequence
according to one embodiment of the present disclosure, and FIG. 4B
is a diagram showing a modification.
[0011] FIGS. 5A and 5B are diagrams showing modifications of the
film forming sequence shown in FIG. 4A, respectively.
DETAILED DESCRIPTION
One Embodiment of the Present Disclosure
[0012] One embodiment of the present disclosure will now be
described in detail with reference to FIGS. 1 to 3.
(1) Configuration of Substrate Processing Apparatus
[0013] As illustrated in FIG. 1, a processing furnace 202 includes
a heater 207 as a heating means (heating mechanism). The heater 207
has a cylindrical shape and is supported by a holding plate so as
to be vertically installed. The heater 207 functions as an
activation mechanism (an excitation part) configured to thermally
activate (excite) a gas.
[0014] A reaction tube 203 that constitutes a reaction vessel
(process vessel) is disposed inside the heater 207 in a concentric
relationship with the heater 207. The reaction tube 203 is made of
a heat resistant material such as, e.g., quartz (SiO.sub.2),
silicon carbide (SiC) or the like and is formed in a cylindrical
shape with its upper end closed and its lower end opened. A process
chamber 201 is formed in a hollow cylindrical portion of the
reaction tube 203. The process chamber 201 is configured to be able
to accommodate wafers 200 as substrates.
[0015] Inside the process chamber 201, nozzles 249a and 249b are
installed so as to penetrate a lower side wall of the reaction tube
203. Gas supply pipes 232a and 232b are connected to the nozzles
249a and 249b, respectively. A gas supply pipe 232c is connected to
the gas supply pipe 232b.
[0016] Mass flow controllers (MFCs) 241a to 241c as flow rate
controllers (flow rate control parts) and valves 243a to 243c as
on-off valves are respectively installed in the gas supply pipes
232a to 232c sequentially from respective upstream sides. Gas
supply pipes 232d and 232e for supplying an inert gas are
respectively connected to the gas supply pipes 232a and 232b at
downstream sides of the valves 243a and 243b. MFCs 241d and 241e
and valves 243d and 243e are respectively installed in the gas
supply pipes 232d and 232e sequentially from respective upstream
sides.
[0017] As shown in FIG. 2, the nozzles 249a and 249b are installed
in a space having an annular plan-view shape between the inner wall
of the reaction tube 203 and the wafers 200 so as to extend upward
in an arrangement direction of the wafers 200 from the lower
portion of the inner wall of the reaction tube 203 to the upper
portion thereof. In other words, the nozzles 249a and 249b are
respectively installed at a lateral side of a wafer arrangement
region in which the wafers 200 are arranged, in a region
horizontally surrounding the wafer arrangement region, so as to
extend along the wafer arrangement region. Gas supply holes 250a
and 250b through which gases are supplied are formed in side
surfaces of the nozzles 249a and 249b, respectively. The gas supply
holes 250a and 250b are respectively opened so as to face the
center of the reaction tube 20 so that the gas supply holes 250a
and 250b can supply respective gases to the wafers 200. The gas
supply holes 250a and 250b are installed in a plural number over a
region spanning from the lower portion of the reaction tube 203 to
the upper portion thereof.
[0018] From the gas supply pipe 232a, for example, a halogen-based
precursor gas containing Si or Ge and containing a halogen element
as a first process gas is supplied into the process chamber 201 via
the MFC 241a, the valve 243a and the nozzle 249a. The precursor gas
is a gas in a gaseous state, for example, a gas obtained by
vaporizing a precursor remaining in a liquid state under room
temperature and atmospheric pressure, a precursor remaining in a
gaseous state under room temperature and atmospheric pressure, or
the like. The halogen element includes chlorine (Cl), fluorine (F),
bromine (Br), iodine (I), and the like. That is to say, the
halogen-based precursor gas includes a halogen group such as a
chloro group, a fluoro group, a bromo group, an iodine group, and
the like. As the halogen-based precursor gas, it may be possible to
use, for example, a halosilane precursor gas containing Si and Cl,
namely a chlorosilane precursor gas, or a halogermane precursor gas
containing Ge and Cl, namely a chlorogermane precursor gas. As the
chlorosilane precursor gas, it may be possible to use, for example,
a dichlorosilane (SiH.sub.2Cl.sub.2, abbreviation: DCS) gas. As the
chlorogermane precursor gas, it may be possible to use, for
example, a dichlorogermane (GeH.sub.2Cl.sub.2, abbreviation: DCG)
gas.
[0019] From the gas supply pipe 232b, for example, a
non-halogen-based silane precursor gas containing Si and not
containing a halogen element as a second process gas is supplied
into the process chamber 201 via the MFC 241b, the valve 243b and
the nozzle 249b. As the second process gas, it may be possible to
use a silicon hydride precursor gas, for example, a disilane
(Si.sub.2H.sub.6, abbreviation: DS) gas.
[0020] From the gas supply pipe 232c, for example, a
non-halogen-based germane precursor gas containing Ge and not
containing a halogen element as a third process gas and a fourth
process gas is supplied into the process chamber 201 via the MFC
241c, the valve 243c, the gas supply pipe 232b and the nozzle 249b.
As the third process gas and the fourth process gas, it may be
possible to use a germanium hydride precursor gas, for example, a
monogermane (GeH.sub.4, abbreviation: MG) gas.
[0021] From the gas supply pipes 232d and 232e, for example, a
nitrogen (N.sub.2) gas as an inert gas is supplied into the process
chamber 201 via the MFCs 241d and 241e, the valves 243d and 243e,
the gas supply pipes 232a and 232b, and the nozzles 249a and 249b,
respectively.
[0022] A first supply system (a halosilane precursor supply system
or a halogermane precursor supply system) is mainly configured by
the gas supply pipe 232a, the MFC 241a and the valve 243a. A second
supply system (a silicon hydride precursor supply system) is mainly
configured by the gas supply pipe 232b, the MFC 241b and the valve
243b. A third supply system (germanium hydride precursor supply
system) is mainly configured by the gas supply pipe 232c, the MFC
241c and the valve 243c. An inert gas supply system is mainly
configured by the gas supply pipes 232d and 232e, the MFCs 241d and
241e, and the valves 243d and 243e.
[0023] One or all of the above-described various supply systems may
be configured as an integrated supply system 248 in which the
valves 243a to 243e, the MFCs 241a to 241e, and the like are
integrated. The integrated supply system 248 is connected to the
respective gas supply pipes 232a to 232e and is configured so that
the operations of supplying various gases into the gas supply pipes
232a to 232e, namely the opening and closing operations of the
valves 243a to 243e, the flow rate adjustment operations of the
MFCs 241a to 241e, and the like, are controlled by a controller 121
which will be described later. The integrated supply system 248 is
configured as integral type or divisional type integrated units and
can be attached to and detached from the gas supply pipes 232a to
232e or the like on an integrated unit basis. The integrated supply
system 248 is configured so that the maintenance, replacement and
expansion of the supply systems can be performed on an integrated
unit basis.
[0024] An exhaust pipe 231 for exhausting an internal atmosphere of
the process chamber 201 is installed in the reaction tube 203. A
vacuum pump 246 as a vacuum exhaust device is coupled to the
exhaust pipe 231 via a pressure sensor 245 as a pressure detector
(pressure detection part) for detecting an internal pressure of the
process chamber 201 and an APC (Auto Pressure Controller) valve 244
as a pressure regulator (pressure regulation part). The APC valve
244 is configured so that the vacuum evacuation and vacuum
evacuation stop of the interior of the process chamber 201 can be
performed by opening and closing the APC valve 244 while operating
the vacuum pump 246 and so that the internal pressure of the
process chamber 201 can be regulated by adjusting the valve opening
degree of the APC valve 244 based on the pressure information
detected by the pressure sensor 245, while operating the vacuum
pump 246. An exhaust system is mainly configured by the exhaust
pipe 231, the APC valve 244 and the pressure sensor 245. The vacuum
pump 246 may be included in the exhaust system.
[0025] A seal cap 219 as a furnace opening lid capable of
air-tightly closing a lower end opening of the reaction tube 203 is
installed below the reaction tube 203. The seal cap 219 is made of
metal such as, e.g., SUS, and is formed in a disc shape. On an
upper surface of the seal cap 219, there is installed an O-ring 220
as a seal member which is brought into contact with a lower end of
the reaction tube 203. Below the seal cap 219, there is installed a
rotation mechanism 267 configured to rotate a boat 217 to be
described later. A rotary shaft 255 of the rotation mechanism 267
penetrates the seal cap 219 and is connected to the boat 217. The
rotation mechanism 267 is configured to rotate the wafers 200 by
rotating the boat 217. The seal cap 219 is configured to be moved
up and down in the vertical direction by a boat elevator 115 as an
elevating mechanism installed outside the reaction tube 203. The
boat elevator 115 is configured as a conveying device (conveying
mechanism) which loads and unloads (conveys) the boat 217, namely
the wafers 200, into and out of the process chamber 201 by raising
and lowering the seal cap 219.
[0026] The boat 217 serving as a substrate supporting part is
configured to support a plurality of, e.g., 25 to 200, wafers 200,
in such a state that the wafers 200 are arranged in a horizontal
posture and in multiple stages along a vertical direction with the
centers of the wafers 200 aligned with one another. That is to say,
the boat 217 is configured to arrange the wafers 200 in a
spaced-apart relationship. The boat 217 is made of a heat resistant
material such as quartz or SiC. Heat insulating plates 218 made of
a heat resistant material such as, e.g., quartz or SiC, are
supported below the boat 217 in a horizontal posture and in
multiple stages.
[0027] A temperature sensor 263 serving as a temperature detector
is installed inside the reaction tube 203. Based on the temperature
information detected by the temperature sensor 263, an amount of
electric power supplied to the heater 207 is adjusted such that the
interior of the process chamber 201 has a desired temperature
distribution. The temperature sensor 263 is installed along the
inner wall of the reaction tube 203.
[0028] As illustrated in FIG. 3, the controller 121, which is a
control part (control means), may be configured as a computer
including a central processing unit (CPU) 121a, a random access
memory (RAM) 121b, a memory device 121c, and an I/O port 121d. The
RAM 121b, the memory device 121c and the I/O port 121d are
configured to exchange data with the CPU 121a via an internal bus
121e. An input/output device 122 configured by, for example, a
touch panel or the like, is connected to the controller 121.
[0029] The memory device 121c is configured by, for example, a
flash memory, a hard disk drive (HDD), or the like. A control
program for controlling operations of a substrate processing
apparatus, a process recipe for specifying sequences and conditions
of a substrate process to be described later, or the like is
readably stored in the memory device 121c. The process recipe
functions as a program for causing the controller 121 to execute
each sequence in the substrate process (to be described later) to
obtain a predetermined result. Hereinafter, the process recipe and
the control program will be generally and simply referred to as a
"program". Furthermore, the process recipe will be simply referred
to as a "recipe". When the term "program" is used herein, it may
indicate a case of including only the recipe, a case of including
only the control program, or a case of including both the recipe
and the control program. The RAM 121b is configured as a memory
area (work area) in which a program or data read by the CPU 121a is
temporarily stored.
[0030] The I/O port 121d is connected to the MFCs 241a to 241e, the
valves 243a to 243e, the pressure sensor 245, the APC valve 244,
the vacuum pump 246, the heater 207, the temperature sensor 263,
the rotation mechanism 267, the boat elevator 115, and the
like.
[0031] The CPU 121a is configured to read the control program from
the memory device 121c and execute the same. The CPU 121a also
reads the recipe from the memory device 121c according to an
operation command input provided from the input/output device 122.
In addition, the CPU 121a is configured to control, according to
the contents of the recipe thus read, the flow rate adjusting
operations of various kinds of gases by the MFCs 241a to 241e, the
opening/closing operations of the valves 243a to 243e, the
opening/closing operation of the APC valve 244, the pressure
regulating operation performed by the APC valve 244 based on the
pressure sensor 245, the driving and stopping of the vacuum pump
246, the temperature adjusting operation performed by the heater
207 based on the temperature sensor 263, the operation of rotating
the boat 217 with the rotation mechanism 267 and adjusting the
rotation speed of the boat 217, the operation of moving the boat
217 up and down with the boat elevator 115, and the like.
[0032] The controller 121 may be configured by installing, on the
computer, the aforementioned program stored in an external memory
device 123 (for example, a magnetic disc such as a hard disc or the
like, an optical disc such as a CD or the like, a magneto-optical
disc such as an MO or the like, or a semiconductor memory such as a
USB memory or the like). The memory device 121c or the external
memory device 123 is configured as a non-transitory
computer-readable recording medium. Hereinafter, the memory device
121c and the external memory device 123 will be generally and
simply referred to as a "recording medium." When the term
"recording medium" is used herein, it may indicate a case of
including only the memory device 121c, a case of including only the
external memory device 123, or a case of including both the memory
device 121c and the external memory device 123. Furthermore, the
program may be supplied to the computer using communication means
such as the Internet or a dedicated line, instead of using the
external memory device 123.
(2) Substrate Processing Steps
[0033] A sequence example of forming a germanium film (Ge film) on
the wafer 200 as a substrate using the aforementioned substrate
processing apparatus, which is one of the processes for
manufacturing a semiconductor device, will be described below with
reference to FIG. 4A. In the following descriptions, the operations
of the respective parts constituting the substrate processing
apparatus are controlled by the controller 121.
[0034] In the film forming sequence shown in FIG. 4A, there are
performed:
[0035] a step (SiGe seed layer forming step) of forming a SiGe seed
layer as a first seed layer containing Si and Ge on the wafer 200
by performing, a predetermined number of times, a first cycle
including step 1a of supplying a DCS gas to the wafer 200, step 2a
of supplying a DS gas to the wafer 200 and step 3a of supplying an
MG gas to the wafer 200; and a step (Ge film forming step) of
forming a Ge film as a Ge-containing film on the SiGe seed layer by
supplying the MG gas to the wafer 200.
[0036] In the present disclosure, the film forming sequence shown
in FIG. 4A may be denoted as follows for the sake of convenience.
Similar notations are also used in the following descriptions of
modifications and the like.
[0037] (DCS.fwdarw.DS.fwdarw.MG).times.n.sub.1.fwdarw.MGGe
film/SiGe seed
[0038] When the term "wafer" is used herein, it may refer to a
wafer itself or a laminated body of a wafer and a predetermined
layer or film formed on the surface of the wafer. When the phrase
"a surface of a wafer" is used herein, it may refer to a surface of
a wafer itself or a surface of a predetermined layer or the like
formed on a wafer. In the present disclosure, the expression "a
predetermined layer is formed on a wafer" may mean that a
predetermined layer is directly formed on a surface of a wafer
itself or that a predetermined layer is formed on a layer or the
like formed on a wafer. When the term "substrate" is used herein,
it may be synonymous with the term "wafer."
(Wafer Charging and Boat Loading)
[0039] The plurality of wafers 200 are charged into the boat 217
(wafer charging). Thereafter, as shown in FIG. 1, the boat 217
supporting the plurality of wafers 200 is lifted by the boat
elevator 115 and is loaded into the process chamber 201 (wafer
loading). In this state, the seal cap 219 seals the lower end of
the reaction tube 203 via the O-ring 220.
[0040] As the wafer 200, for example, a Si substrate formed of
monocrystalline Si or a substrate having a monocrystalline Si film
formed on its surface may be used. The monocrystalline Si remains
exposed on the surface of the wafer 200. An insulating film such
as, e.g., a silicon oxide film (SiO film), a silicon nitride film
(SiN film), a silicon oxynitride film (SiON film), or the like may
be formed on a portion of the surface of the wafer 200.
[0041] Before the wafers 200 are loaded into the process chamber
201, the surface of each of the wafers 200 is cleaned beforehand
with hydrogen fluoride (HF) or the like. However, after the
cleaning process, the surface of each of the wafers 200 is
temporarily exposed to the atmosphere until the wafers 200 are
loaded into the process chamber 201. Therefore, a natural oxide
film (SiO film) is formed on at least a portion of the surface of
the wafer 200 loaded into the process chamber 201. The natural
oxide film may be formed so as to sparsely (in an island shape)
cover the surface of the wafer 200, namely a portion of the exposed
monocrystalline Si, or may be formed so as to continuously (in a
non-island shape) cover the entire region of the exposed
monocrystalline Si.
(Pressure Regulation and Temperature Adjustment)
[0042] The interior of the process chamber 201, namely the space in
which the wafers 200 are located, is vacuum-exhausted
(depressurization-exhausted) by the vacuum pump 246 so as to reach
a desired pressure (degree of vacuum). In this operation, the
internal pressure of the process chamber 201 is measured by the
pressure sensor 245. The APC valve 244 is feedback-controlled based
on the measured pressure information. The vacuum pump 246 may be
continuously activated at least until the process of the wafers 200
is completed. The wafers 200 in the process chamber 201 are heated
by the heater 207 to a desired film formation temperature. In this
operation, the state of supplying electric power to the heater 207
is feedback-controlled based on the temperature information
detected by the temperature sensor 263 such that the interior of
the process chamber 201 has a desired temperature distribution. In
addition, the heating of the interior of the process chamber 201 by
the heater 207 may be continuously performed at least until the
process of the wafers 200 is completed. The rotation of the boat
217 and the wafers 200 by the rotation mechanism 267 begins. The
rotation of the boat 217 and the wafers 200 may be continuously
performed at least until the process of the wafers 200 is
completed.
(SiGe Seed Layer Forming Step)
[0043] Thereafter, steps 1a to 3a are sequentially executed.
[Step 1a]
[0044] In this step, a DCS gas is supplied to the wafer 200.
Specifically, the valve 243a is opened to allow the DCS gas to flow
through the gas supply pipe 232a. A flow rate of the DCS gas is
adjusted by the MFC 241a. The DCS gas is supplied into the process
chamber 201 via the nozzle 249a and is exhausted from the exhaust
pipe 231. At this time, the DCS gas is supplied to the wafer 200.
At the same time, the valve 243d is opened to allow a N.sub.2 gas
to flow through the gas supply pipe 232d. The N.sub.2 gas is
supplied into the process chamber 201 together with the DCS gas and
is exhausted from the exhaust pipe 231. In order to prevent the DCS
gas from entering the nozzle 249b, the valve 243e is opened to
allow the N.sub.2 gas to flow through the gas supply pipe 232e. The
N.sub.2 gas is supplied into the process chamber 201 via the gas
supply pipe 232b and the nozzle 249b and is exhausted from the
exhaust pipe 231.
[0045] By supplying the DCS gas to the wafer 200, it is possible to
generate a DCS-based treatment effect and to perform the following
process. That is to say, by supplying DCS containing Cl having high
electronegativity to the surface of the wafer 200, oxygen (O) in
the natural oxide film formed on the surface of the wafer 200 and
Cl in the DCS can be caused to meet with each other, thereby
breaking a Si--O bond contained in the natural oxide film. In other
words, the Si--O bond terminating at the surface of the
monocrystalline Si can be broken by the polarity of DCS. In
addition, the Si--O bond terminating at the surface of the
monocrystalline Si can be broken by a small amount of Cl.sup.- (Cl
ions) generated by the separation from DCS. As a result, a dangling
bond of Si can be generated on the surface of the monocrystalline
Si. This makes it possible to create an environment in which the
epitaxial growth to be described later is easy to proceed. On the
surface of the wafer 200, the above-described reaction proceeds,
whereby the natural oxide film formed on the surface of the wafer
200 is removed so that the surface of the monocrystalline Si is
exposed. In this manner, the DCS gas acts as a cleaning gas for
removing the natural oxide film from the surface of the
monocrystalline Si. In the case where a SiO film or the like is
formed on the surface of the wafer 200, a Si adsorption site is
formed on the surface of the SiO film or the like due to the
above-described treatment effect.
[0046] After the environment where the epitaxial growth is easy to
occur on the surface of the wafer 200 is established by the
treatment effect described above, the valve 243a is closed to stop
the supply of the DCS gas. At this time, while keeping the APC
valve 244 opened, the interior of the process chamber 201 is
evacuated such that the unreacted gas which is the remaining gas
after the aforementioned reaction in the process chamber 201, is
removed from the interior of the process chamber 201. At this time,
the valves 243d and 243e are kept opened to maintain the supply of
the N.sub.2 gas into the process chamber 201. The N.sub.2 gas acts
as a purge gas.
[Step 2a]
[0047] After step 1a is completed, a DS gas is supplied to the
wafer 200. In this step, controlling the opening and closing
operations of the valves 243b, 243d and 243e is performed in the
same procedure as controlling the opening and closing operations of
the valves 243a, 243d and 243e in step 1a, whereby the DS gas is
caused to flow into the gas supply pipe 232b. A flow rate of the DS
gas flowing through the gas supply pipe 232b is adjusted by the MFC
241b. The DS gas is supplied into the process chamber 201 via the
nozzle 249b and is exhausted from the exhaust pipe 231. At this
time, the DS gas is supplied to the wafer 200.
[0048] By supplying the DS gas to the wafer 200, Si contained in
the DS can be bonded to the dangling bond of Si formed in step 1a.
As a result, nuclei of Si crystals (Si nuclei) can be formed on the
surface of the wafer 200. Si crystals can be subjected to the
epitaxial growth (gas-phase epitaxial growth). This growth is
homoepitaxial growth. In the homoepitaxial growth, on the
underlying crystals, crystals having the same lattice constant as
the underlying crystals and made of the same material as the
underlying crystals grow in the same crystal orientation as the
underlying crystals. It is therefore possible to obtain
less-defective high quality crystals. In the case where a SiO film
or the like is formed on the surface of the wafer 200, Si contained
in DS can be adsorbed onto the Si adsorption sites formed on the
surface of the SiO film or the like by the aforementioned treatment
effect. In this case, Si nuclei having an amorphous state, a
polycrystalline state or a mixed crystal state in which an
amorphous state and a polycrystalline state are mixed with each
other, are formed on the SiO film.
[0049] After the formation of the Si nuclei is completed, the valve
243b is closed to stop the supply of the DS gas. Then, by the same
process procedure as in step 1a, the unreacted gas, which is the
remaining gas after the above reaction or the reaction byproduct
remaining in the process chamber 201, is removed from the interior
of the process chamber 201.
[Step 3a]
[0050] After step 2a is completed, an MG gas is supplied to the
wafer 200. In this step, controlling the opening and closing
operations of the valves 243c, 243d and 243e is performed in the
same procedure as controlling the opening and closing operations of
the valves 243a, 243d and 243e in step 1a so that the MG gas flows
through the gas supply pipe 232c. A flow rate of the MG gas flowing
through the gas supply pipe 232c is adjusted by the MFC 241c. The
MG gas is supplied into the process chamber 201 via the gas supply
pipe 232b and the nozzle 249b and is exhausted from the exhaust
pipe 231. At this time, the MG gas is supplied to the wafer
200.
[0051] By supplying the MG gas to the wafer 200, Ge contained in MG
can be bonded to the dangling bond of Si formed in step 1a or the
dangling bond of Si constituting the Si nuclei formed in step 2a.
As a result, nuclei of SiGe crystals (SiGe nuclei) can be formed on
the surface of the wafer 200, and SiGe crystals can be caused to
epitaxially grow in a gas phase. This growth is the heteroepitaxial
growth. In the heteroepitaxial growth, crystals having the same
crystal structure as the underlying crystals and made of a material
different from the material of the underlying crystals grow in the
same crystal orientation on the underlying crystals. In the case
where an SiO film or the like is formed on the surface of the wafer
200, Ge contained in MG can be adsorbed to the Si adsorption site
formed on the surface of the SiO film or the like, or the Si
adsorption site of Si nuclei, by the treatment effect described
above. In this case, SiGe nuclei in an amorphous state, a
polycrystalline state or a mixed crystal state in which an
amorphous state and a polycrystalline state are mixed with each
other, are formed on the SiO film.
[0052] After the formation of the SiGe nuclei is completed, the
valve 243c is closed to stop the supply of the MG gas. Then, by the
same process procedure as in step 1a, the unreacted gas, which is
the remaining gas after the aforementioned reaction, or the
reaction byproduct remaining in the process chamber 201, is removed
from the interior of the process chamber 201.
[0053] When steps 2a and 3a are performed, at least a portion of
the surface of the wafer 200 may remain terminated with a Si--H
bond contained in the DS gas or a Ge--H bond contained in the MG
gas in some cases. The Si--H bond or the Ge--H bond terminating at
the surface of the wafer 200 can be broken by supplying the DCS gas
to the wafer 200 in the subsequent step 1a. That is to say, the
Si--H bond or the Ge--H bond terminating at the surface of the
wafer 200 can be broken by a small amount of Cl.sup.- generated by
the separation from DCS. As a result, a dangling bond of Si or Ge
can be formed on the surface of the wafer 200. In other words, on
the surface of the wafer 200, an environment where the epitaxial
growth is easy to occur can be established again. Thus, in the
subsequent steps 2a and 3a, the formation of the Si nuclei or the
SiGe nuclei described above is started without delay.
[0054] If steps 2a and 3a are performed, Si nuclei or SiGe nuclei
may abnormally grow on the surface of the wafer 200 in some cases.
For example, when steps 2a and 3a are performed, Si or Ge adsorbed
onto the surface of the wafer 200 may locally agglomerate and a
convex-concave structure may be formed on the surface of the wafer
200 in some cases. However, the abnormally grown nuclei can be
removed by supplying the DCS gas to the wafer 200 in the subsequent
step 1a. That is to say, a Si--Si bond, a Ge--Ge bond and a Si--Ge
bond contained in the abnormally grown nuclei can be broken by a
small amount of Cl.sup.- generated by the separation from DCS,
thereby etching the abnormally grown nuclei. Thus, the surface of
the layer formed in the SiGe seed layer forming step can be
smoothened. As a result, it is possible to improve the surface
roughness or the like of the finally formed Ge film. Here, the term
"surface roughness" refers to a height difference (having the same
meaning as that of surface coarseness) of a film in in-plane of the
wafer. Further, the surface roughness may indicate that the surface
becomes smoother as its value grows smaller. That is to say, the
expression "the surface roughness is enhanced" refers to the fact
that a difference in height of a film is reduced to enhance the
smoothness of the surface.
[0055] Each of the effects described here may be considered to be
included in the DCS-based treatment effect.
[Performing a Predetermined Number of Times]
[0056] A cycle of performing steps 1a to 3a in this order, i.e.,
non-simultaneously without synchronization, is performed a
predetermined number of times (n.sub.1 times where n.sub.1 is an
integer of 1 or more). As a result, a SiGe seed layer can be formed
on the surface of the wafer 200. The SiGe seed layer is formed by
epitaxially growing a SiGe crystal with the surface of the wafer
200 used as a base. The crystal structure of the SiGe seed layer is
a monocrystal inheriting the crystallinity of the base. That is to
say, the SiGe seed layer is a monocrystalline SiGe layer (epitaxial
SiGe layer) having the same crystal orientation as the underlying
monocrystalline Si.
[0057] Hereinafter, the process conditions of the SiGe seed layer
forming step will be described. The conditions shown here are also
conditions that enable the above-mentioned treatment effect to be
exhibited properly.
[0058] The supply flow rates of the process gases (the DCS gas, the
DS gas and the MG gas) in steps 1a to 3a are respectively set to
predetermined flow rates within a range of, for example, 10 to
2,000 sccm. The supply time periods of the process gases in steps
1a to 3a are respectively set to predetermined time periods within
a range of, for example, 1 to 60 minutes. In steps 1a to 3a, the
supply flow rates of the N.sub.2 gas supplied from the respective
gas supply pipes are respectively set to predetermined flow rates
within a range of, for example, 0 to 10,000 sccm. By not supplying
the N.sub.2 gas, it becomes possible to increase a partial pressure
of each process gas and to improve the layer quality.
[0059] The temperature (film formation temperature) of the wafer
200 is set to a temperature within a range of, for example, 250 to
450 degrees C., specifically 300 to 400 degrees C. The internal
pressure (film formation pressure) of the process chamber 201 is
set to a pressure within a range of, for example, 0.1 to 10 Torr
(13.3 to 1,330 Pa).
[0060] If the film formation temperature is less than 250 degrees
C. or if the film formation pressure is less than 0.1 Torr, the
amount of Cl.sup.- or DCS supplied to the wafer 200 in step 1a may
be insufficient and the treatment effect described above may not be
obtained in some cases. Furthermore, the DS and MG supplied to the
wafer 200 in steps 2a and 3a may be less likely to be decomposed
and the formation of the SiGe seed layer on the wafer 200 may be
difficult in some cases. By setting the film formation temperature
to 250 degrees C. or higher or by setting the film formation
pressure to 0.1 Torr or more, it is possible to solve these
problems and to form the SiGe seed layer at a practical rate. By
setting the film formation temperature to 300 degrees C. or higher,
it is possible to more reliably solve these problems and to further
increase the formation rate of the SiGe seed layer.
[0061] If the film formation temperature exceeds 450 degrees C. or
if the film formation pressure exceeds 10 Torr, in step 1a, Si
contained in DCS may be deposited on the wafer 200 in some cases.
In this case, Si is deposited before the natural oxide film is
removed from the surface of the monocrystalline Si. The epitaxial
growth does not proceed on the monocrystalline Si (on the natural
oxide film). The finally obtained SiGe seed layer may become an
amorphous layer or a polycrystalline layer in some cases.
Furthermore, the treatment effect using the polarity of DCS or the
like may not be obtained in some cases. In addition, an excessive
gas phase reaction occurs in steps 2a and 3a. Thus, the thickness
uniformity or the step coverage of the SiGe seed layer may be
deteriorated in some cases. Moreover, the amount of particles
generated inside the process chamber 201 may increase in some
cases. These problems can be solved by setting the film formation
temperature to 450 degrees C. or lower or by setting the film
formation pressure to 10 Torr or lower. Thus, the SiGe seed layer
can be made to become a layer with good in-plane film thickness
uniformity or good step coverage. By setting the film formation
temperature to 400 degrees C. or lower, it is possible to more
reliably solve these problems and to further improve the quality of
the SiGe seed layer.
[0062] The number of execution times of the cycle (n.sub.1) is set
to a predetermined number of times within a range of, for example,
5 to 20 times, specifically 10 to 15 times. Thus, the thickness of
the SiGe seed layer to be formed in this way can be set to a
predetermined thickness within a range of, for example, 10 to 40
.ANG. (1 to 4 nm), specifically 20 to 30 .ANG. (2 to 3 nm).
Incidentally, by performing the cycle a plurality of times, it is
possible to increase the density of the SiGe seed layer and to
prevent the SiGe seed layer from growing in an island shape. As a
result, the Ge film formed on the SiGe seed layer can be formed
into a dense film with good surface roughness and less film
breakage or the like.
[0063] As the first process gas, in addition to the DCS gas, it may
be possible to use a chlorosilane precursor gas such as
monochlorosilane (SiH.sub.3Cl, abbreviation: MCS) gas, a
trichlorosilane (SiHCl.sub.3, abbreviation: TCS) gas, a
tetrachlorosilane (SiCl.sub.4, abbreviation: STC) gas, a
hexachlorodisilane (Si.sub.2Cl.sub.6, abbreviation: HCDS) gas or
the like, or a chlorogermane precursor gas such as a
monochlorogermane (GeH.sub.3Cl, abbreviation: MCG) gas, a DCG gas,
a trichlorogermane (GeHCl.sub.3, abbreviation: TCG) gas, a
tetrachlorogermane (GeCl.sub.4, abbreviation: GTC) gas, a
hexachlorodigermane (Ge.sub.2Cl.sub.6, abbreviation: HCDG) gas or
the like. In step 1a, in order to promote the above-described
breakage reaction of a Si--O bond while suppressing the deposition
of Si or Ge on the wafer 200, a precursor gas having a small number
of Si or Ge contained in one molecule and having a large number of
Cl contained in one molecule may be used as the first process gas.
In step 1a, in order to properly suppress the treatment effect
described above, a precursor gas having a small number of Cl
contained in one molecule may be used.
[0064] As the second process gas, in addition to the DS gas, it may
be possible to use a silicon hydride precursor gas such as a
monosilane (SiH.sub.4) gas, a trisilane (Si.sub.3H.sub.8) gas, a
tetrasilane (Si.sub.4H.sub.10) gas, a pentasilane
(Si.sub.5H.sub.12) gas, a hexasilane (Si.sub.6H.sub.14) gas or the
like, namely a silane precursor gas containing no halogen
element.
[0065] As the third process gas, in addition to the MG gas, it may
be possible to use a germanium hydride precursor gas such as a
digermane (Ge.sub.2H.sub.6) gas, a trigermane (Ge.sub.3H.sub.8)
gas, a tetragermane (Ge.sub.4H.sub.10) gas, a pentagermane
(Ge.sub.5H.sub.12) gas, a hexagermane (Ge.sub.6H.sub.14) gas or the
like, namely a germane precursor gas containing no halogen
element.
[0066] As the inert gas, in addition to the N.sub.2 gas, it may be
possible to use, for example, a rare gas such as an Ar gas, a He
gas, a Ne gas, a Xe gas or the like.
(Ge Film Forming Step)
[0067] After the SiGe seed layer forming step is completed, the MG
gas is supplied to the wafer 200. In this step, the MG gas is
caused to flow through the gas supply pipe 232c by the same
procedure as that of step 3a described above. The MG gas flowing
through the gas supply pipe 232c is supplied into the process
chamber 201 and is supplied to the wafer 200. Thereafter, the MG
gas is exhausted from the exhaust pipe 231.
[0068] By supplying the MG gas to the wafer 200, a Ge crystal
having the same crystal structure as the SiGe crystal can be caused
to epitaxially grow in a gas phase on the SiGe seed layer, thereby
forming a Ge film (epitaxial Ge film) made of monocrystalline Ge.
This growth is the heteroepitaxial growth. Since the lattice
constant of the SiGe crystal is closer to the lattice constant of
the Ge crystal than the lattice constant of the Si crystal, in the
heteroepitaxial growth using the SiGe seed layer as a base, it is
possible to obtain a high-quality crystal having fewer defects than
in the heteroepitaxial growth using the surface of the wafer 200
(monocrystalline Si) as a base. That is to say, in the present
embodiment, the SiGe seed layer forming step is performed in
advance before performing the Ge film forming step. Thus, it is
possible to obtain a high-quality Ge film having smaller internal
stresses and fewer defects than when the Ge film forming step is
performed without performing the SiGe seed layer forming step.
[0069] The supply flow rate of the MG gas is set to a flow rate
within a range of, for example, 10 to 2,000 sccm. The supply time
period of the MG gas can be appropriately determined depending on
the film thickness of the Ge film formed on the wafer 200 or the
like and may be set to a time period within a range of, for
example, 10 to 120 minutes. The supply flow rates of the N.sub.2
gas supplied from the respective gas supply pipes are respectively
set to predetermined flow rates within a range of, for example, 0
to 10,000 sccm. By not supplying the N.sub.2 gas, it becomes
possible to increase the partial pressure of the MG gas and to
improve the film quality. The internal pressure (film formation
pressure) of the process chamber 201 is set to a pressure within a
range of, for example, 0.1 to 20 Torr (13.3 to 2,660 Pa). Other
conditions are the same as the process conditions in the SiGe seed
layer forming step.
[0070] As the fourth process gas, in addition to the MG gas, it may
be possible to use various kinds of germanium hydride precursor
gases mentioned above. From the viewpoint of suppressing the
residual halogen element in the Ge film, a germanium hydride
precursor gas not containing a halogen element may be used as the
fourth process gas. From the viewpoint of improving the film
thickness uniformity of the Ge film, a low-order germanium hydride
precursor gas like the third process gas may be used as the fourth
process gas. That is to say, a gas composed of the same substance
as that constituting the third process gas (a gas having the same
molecular structure as the third process gas) may be used as the
fourth process gas. From the viewpoint of improving the deposition
rate of the Ge film, a high reactive germane precursor gas
containing a halogen element may be used as the fourth process
gas.
[0071] As the inert gas, in addition to the N.sub.2 gas, it may be
possible to use various kinds of rare gases mentioned above.
(After-Purging and Atmospheric Pressure Restoration)
[0072] After the Ge film forming step is completed, a N.sub.2 gas
is supplied into the process chamber 201 from each of the gas
supply pipes 232d and 232e and is exhausted from the exhaust pipe
231. The N.sub.2 gas acts as a purge gas. Thus, the interior of the
process chamber 201 is purged with the inert gas. The gas remaining
in the process chamber 201 and the reaction byproduct are removed
from the interior of the process chamber 201 (after-purging).
Thereafter, the internal atmosphere of the process chamber 201 is
replaced by an inert gas (inert gas replacement), and the internal
pressure of the process chamber 201 is restored to the atmospheric
pressure (atmospheric pressure restoration).
(Boat Unloading and Wafer Discharging)
[0073] The seal cap 219 is moved down by the boat elevator 115 and
the lower end of the reaction tube 203 is opened. Then, the
processed wafers 200 supported by the boat 217 are unloaded from
the lower end of the reaction tube 203 to the outside of the
reaction tube 203 (boat unloading). The processed wafers 200 are
taken out from the boat 217 (wafer discharging).
(3) Effects According to the Present Embodiment
[0074] According to the present embodiment, one or more effects set
forth below may be achieved.
[0075] (a) By forming the SiGe seed layer in advance on the wafer
200 before performing the Ge film forming step, it is possible to
improve the quality of the epitaxial growth as compared with a case
where the Ge film is directly formed on the wafer 200 without
forming the SiGe seed layer. This is because the SiGe seed layer
functions as a buffer layer that absorbs a lattice constant
difference (lattice mismatch) between the Si crystal constituting
the surface of the wafer 200 and the Ge crystal constituting the Ge
film. As a result, it is possible to obtain a Ge film of good
quality with reduced internal stresses or defects, thereby
improving the performance of a finally obtained semiconductor
device and enhancing the manufacturing yield thereof.
[0076] (b) By forming the SiGe seed layer in advance on the wafer
200 before performing the Ge film forming step, it is possible to
enhance the adhesion at the bonding interface between the Ge film
and the wafer 200 or to improve the state of the interface level as
compared with a case where the Ge film is directly formed on the
wafer 200 without forming the SiGe seed layer. This makes it
possible to improve the performance of the finally obtained
semiconductor device and to enhance the manufacturing yield
thereof.
[0077] (c) In the SiGe seed layer forming step, it is possible to
start the epitaxial growth on the surface of the wafer 200 without
delay by the treatment effect exerted by the DCS. In addition, due
to this treatment effect, the SiGe seed layer can be made into a
continuous and dense layer having excellent step coverage and a
planar surface. As a result, the finally formed Ge film can be made
into a film having excellent step coverage, excellent in-plane film
thickness uniformity and extremely good surface roughness.
[0078] (d) By forming the SiGe seed layer in advance on the wafer
200 before performing the Ge film forming step, even if a SiO film
or the like is present on a portion of the surface of the wafer 200
(the base of the film formation) and even if the SiO film or the
like is not completely removed due to the DCS-based treatment
effect, it is possible to enable the SiGe seed layer to function as
an oxidation block layer (diffusion suppressing layer) for
suppressing the diffusion of O from the base to the Ge film. As a
result, it is possible to suppress the oxidation of the finally
formed Ge film.
[0079] (e) The above-described effects can be similarly obtained
when a precursor gas containing a halogen element other than the
DCS gas is used as the first process gas, when a silicon hydride
precursor gas other than the DS gas is used as the second process
gas, or when a germanium hydride precursor gas other than MG gas is
used as the third process gas or the fourth process gas. In the
case where a gas not containing a halogen element, such as a
silicon hydride precursor gas, a germanium hydride precursor gas,
an aminosilane precursor gas, an aminogermane precursor gas or the
like, is used as the first process gas, the treatment effect
described above is not obtained.
(4) Modifications
[0080] The film forming sequence according to the present
embodiment is not limited to the above-described aspects and may be
changed as in the following modifications.
(Modification 1)
[0081] As in the film forming sequences shown below, in the SiGe
seed layer forming step, the supply timings of the respective
process gases may be changed from the film forming sequence shown
in FIG. 4A. The process procedures and process conditions of the
respective steps may be the same as those of the respective steps
of the film forming sequence shown in FIG. 4A except for the gas
supply timings.
[0082] (DCS.fwdarw.MG.fwdarw.DS).times.n.sub.1.fwdarw.MGGe
film/SiGe seed
[0083] (DCS.fwdarw.DS+MG).times.n.sub.1.fwdarw.MGGe film/SiGe
seed
[0084] Even with these modifications, the same effects as those of
the film forming sequence shown in FIG. 4A can be obtained. In each
cycle, the film forming sequence for supplying gases in the order
of DCS.fwdarw.DS.fwdarw.MG or in the order of
DCS.fwdarw.DS.fwdarw.MG is more preferable than the film forming
sequence for supplying gases in the order of
DCS.fwdarw.MG.fwdarw.DS, in that it is easy to perform the reliable
and high-quality epitaxial growth using the surface of the wafer
200 as a base.
(Modification 2)
[0085] As in the film forming sequence shown in FIG. 4B or the
following film forming sequences, a Si seed layer forming step may
be performed before performing the SiGe seed layer forming step. In
the Si seed layer forming step, for example, a cycle which
alternately performs step 1b of supplying a DCS gas to the wafer
200 and step 2b of supplying a DS gas to the wafer 200 is performed
a predetermined number of times (n.sub.2 times where n.sub.z is an
integer of 1 or more), whereby a second seed layer (Si seed layer)
containing Si is formed on the wafer 200. The Si seed layer is a
monocrystalline Si layer (epitaxial Si layer). The process
procedures and process conditions of steps 1b and 2b may be the
same as those of steps 1a and 2a of the film forming sequence shown
in FIG. 4A.
[0086]
(DCS.fwdarw.DS).times.n.sub.2.fwdarw.(DCS.fwdarw.DS.fwdarw.MG).time-
s.n.sub.1.fwdarw.MGGe film/SiGe seed/Si seed
[0087]
(DCS.fwdarw.DS).times.n.sub.2.fwdarw.(DCS.fwdarw.MG.fwdarw.DS).time-
s.n.sub.1.fwdarw.MGGe film/SiGe seed/Si seed
[0088]
(DCS.fwdarw.DS).times.n.sub.2.fwdarw.(DCS.fwdarw.DS+MG).times.n.sub-
.1.fwdarw.MGGe film/SiGe seed/Si seed
[0089] Even with these modifications, the same effects as those of
the film forming sequence shown in FIG. 4A can be obtained. In the
Si seed layer forming step, similar to the SiGe seed layer forming
step, due to the treatment effect exerted by the DCS, it is
possible to start the epitaxial growth of the Si seed layer without
delay over the entire surface of the wafer 200. Furthermore, due to
this treatment effect, the Si seed layer can be made into a
continuous and dense layer having the excellent step coverage and a
planar surface. Thus, it is possible to further enhance the quality
of the SiGe seed layer formed thereon. As a result, the finally
formed Ge film can be made into a film having the excellent step
coverage, the excellent in-plane film thickness uniformity and the
better surface roughness.
(Modification 3)
[0090] As in the film forming sequences shown below, the Ge seed
layer forming step may be performed after performing the SiGe seed
layer forming step and before performing the Ge film forming step.
In the Ge seed layer forming step, for example, a cycle which
alternately performs step 1c of supplying a DCG gas to the wafer
200 and step 2c of supplying an MG gas to the wafer 200 is
performed a predetermined number of times (n.sub.3 times where
n.sub.3 is an integer of 1 or more), whereby a third seed layer (Ge
seed layer) containing Ge is formed on the wafer 200. The Ge seed
layer is a monocrystalline Ge layer (epitaxial Ge layer). The
process procedures and process conditions of steps 1c and 2c may be
the same as those of steps 1a and 3a of the film forming sequence
shown in FIG. 4A, except that the DCG gas flows through the gas
supply pipe 232a in step 1a.
[0091]
(DCS.fwdarw.DS.fwdarw.MG).times.n.sub.1.fwdarw.(DCG.fwdarw.MG).time-
s.n.sub.3.fwdarw.MGGe film/Ge seed/SiGe seed
[0092]
(DCS.fwdarw.MG.fwdarw.DS).times.n.sub.1.fwdarw.(DCG.fwdarw.MG).time-
s.n.sub.3.fwdarw.MGGe film/Ge seed/SiGe seed
[0093]
(DCS.fwdarw.DS+MG).times.n.sub.1.fwdarw.(DCG.fwdarw.MG).times.n.sub-
.3.fwdarw.MGGe film/Ge seed/SiGe seed
[0094] Even with these modifications, the same effects as those of
the film forming sequence shown in FIG. 4A can be obtained. In the
Ge seed layer forming step, similar to the SiGe seed layer forming
step, due to the treatment effect exerted by the DCG, it is
possible to start the epitaxial growth of the Ge seed layer without
delay over the entire surface of the wafer 200. Furthermore, due to
this treatment effect, the Ge seed layer can be made into a
continuous and dense layer having the excellent step coverage and a
planar surface. Thus, it is possible to further enhance the quality
of the Ge film formed thereon. As a result, the finally formed Ge
film can be made into a film having the excellent step coverage,
the excellent in-plane film thickness uniformity and the better
surface roughness.
(Modification 4)
[0095] As in the film forming sequence shown below, before
performing the Ge film forming step, a multilayered seed layer
forming step which alternately repeats the aforementioned Si seed
layer forming step and the aforementioned SiGe seed layer forming
step a predetermined number of times (m.sub.1 times where m.sub.1
is an integer of 2 or more) may be performed. In the multilayered
seed layer forming step, a multilayered seed layer in which Si seed
layers and SiGe seed layers are alternately laminated is formed on
the wafer 200. The multilayered seed layer serves as a base for
forming a Ge film.
[0096]
[(DCS.fwdarw.DS).times.n.sub.2.fwdarw.(DCS.fwdarw.DS.fwdarw.MG).tim-
es.n.sub.1].times.m.sub.1.fwdarw.MGGe film/multilayer seed
[0097] When performing the multilayered seed layer forming step,
n.sub.z is made larger than n.sub.1 (n.sub.2>n.sub.1) in the
former-half period of the execution period of the multilayered seed
layer forming step and n.sub.1 is made larger than n.sub.2
(n.sub.1>n.sub.2) in the latter-half period of the execution
period of the multilayered seed layer forming step. That is to say,
when the multilayered seed layer is grown, Si-rich crystals are
grown in the lower layer portion of the multilayered seed layer (on
the side closer to the wafer 200), and Ge-rich crystals are grown
in the upper layer portion of the multilayered seed layer (on the
side closer to the Ge film).
[0098] Even with this modification, the same effects as those of
the film forming sequences shown in FIG. 4A and FIG. 4B can be
obtained. Further, by changing (by applying gradation to) the
composition of the multilayered seed layer over the thickness
direction as described above, the lattice constant difference
between the Si crystal constituting the surface of the wafer 200
and the Ge crystal constituting the Ge film can be more properly
absorbed in the multilayered seed layer. As a result, it is
possible to obtain a Ge film of better quality with smaller
internal stresses and fewer defects.
(Modification 5)
[0099] As in the film forming sequence shown in FIG. 5A or the
following film forming sequences, a SiGe cap layer forming step may
be performed after performing the Ge film forming step. In the SiGe
cap layer forming step, for example, a cycle which includes step 1d
of supplying a DCS gas to the wafer 200, step 2d of supplying a DS
gas to the wafer 200, step 3d of supplying an MG gas to the wafer
200 is performed a predetermined number of times (n.sub.4 times
where n.sub.4 is an integer of 1 or more), whereby a first cap
layer (SiGe cap layer) containing Si and Ge is formed on the wafer
200. The SiGe cap layer is a monocrystalline SiGe layer (epitaxial
SiGe layer). The process procedures and process conditions of the
SiGe cap layer forming step may be the same as those of the SiGe
seed layer forming step of the film forming sequence shown in FIG.
4A or the SiGe seed layer forming step of modification 1. In FIG.
5A, for the sake of convenience, the illustration of the SiGe seed
layer forming step is omitted.
[0100]
(DCS.fwdarw.DS.fwdarw.MG).times.n.sub.1.fwdarw.MG.fwdarw.(DCS.fwdar-
w.DS.fwdarw.MG).times.n.sub.4SiGe cap/Ge film/SiGe seed
[0101]
(DCS.fwdarw.DS.fwdarw.MG).times.n.sub.1.fwdarw.MG.fwdarw.(DCS.fwdar-
w.MG.fwdarw.DS).times.n.sub.4SiGe cap/Ge film/SiGe seed
[0102]
(DCS.fwdarw.DS.fwdarw.MG).times.n.sub.1.fwdarw.MG.fwdarw.(DCS.fwdar-
w.DS+MG).times.n.sub.4SiGe cap/Ge film/SiGe seed
[0103] Even with this modification, the same effects as those of
the film forming sequence shown in FIG. 4A can be obtained. Ge is
more easily oxidized than Si, and germanium oxide (GeO) has a
property of being relatively easy to sublime. Therefore, the Ge
film may be oxidized by a small amount of O component remaining in
the process chamber 201, or may be oxidized when the wafer 200
subjected to the film forming process is exposed to the atmosphere.
The surface state of the Ge film may be deteriorated. In contrast,
if the SiGe cap layer made of SiGe having the higher oxidation
resistance than Ge is formed on the Ge film as in the present
embodiment, it is possible to suppress the oxidation of the surface
of the Ge film and to stabilize (passivate) the surface of the Ge
film. That is to say, it is possible to protect the surface state
of the Ge film while maintaining the good state available
immediately after the film formation.
(Modification 6)
[0104] As in the film forming sequence shown in FIG. 5B or the
following film forming sequences, a Si cap layer forming step may
be performed after performing the SiGe cap layer forming step.
Furthermore, after performing the Ge film forming step, the Si cap
layer forming step may be performed without performing the SiGe cap
layer forming step. In the Si cap layer forming step, for example,
a cycle which includes step 1e of supplying a DCS gas to the wafer
200 and step 2e of supplying a DS gas to the wafer 200 is performed
a predetermined number of times (n.sub.5 times where n.sub.5 is an
integer of 1 or more), whereby a second cap layer (Si cap layer)
containing Si is formed on the wafer 200 (on the SiGe cap layer or
the Ge film). The Si cap layer is a monocrystalline Si layer
(epitaxial Si layer). The process procedures and process conditions
of steps 1e and 2e may be the same as those of steps 1a and 2a of
the film forming sequence shown in FIG. 4A. In FIG. 5B, for the
sake of convenience, the illustration of the SiGe seed layer
forming step is omitted.
[0105]
(DCS.fwdarw.DS.fwdarw.MG).times.n.sub.1.fwdarw.MG.fwdarw.(DCS.fwdar-
w.DS.fwdarw.MG).times.n.sub.4.fwdarw.(DCS.fwdarw.DS).times.n.sub.5Si
cap/SiGe cap/Ge film/SiGe seed
[0106]
(DCS.fwdarw.DS.fwdarw.MG).times.n.sub.1.fwdarw.MG.fwdarw.(DCS.fwdar-
w.DS).times.n.sub.5Si cap/Ge film/SiGe seed
[0107] Even with these modifications, the same effects as those of
the film forming sequence shown in FIG. 4A can be obtained.
Further, by forming the Si cap layer made of Si having the higher
oxidation resistance than SiGe on the SiGe cap layer or the Ge
film, it is possible to more reliably suppress the oxidation of the
surface of the Ge film and to more reliably stabilize the surface
of the Ge film.
(Modification 7)
[0108] As in the film forming sequence shown below, after
performing the Ge film forming step, a multilayered cap layer
forming step which alternately repeats the above-described SiGe cap
layer forming step and the above-described Si cap layer forming
step a predetermined number of times (m.sub.2 times where m.sub.2
is an integer of 2 or more) may be performed. In the multilayered
cap layer forming step, a multilayered cap layer in which SiGe cap
layers and Si cap layers are alternately laminated is formed on the
wafer 200. The multilayered cap layer serves as a protective layer
of the Ge film.
[0109]
(DCS.fwdarw.DS.fwdarw.MG).times.n.sub.1.fwdarw.MG.fwdarw.[(DCS.fwda-
rw.DS.fwdarw.MG).times.n.sub.4.fwdarw.(DCS.fwdarw.DS).times.n.sub.5].times-
.m.sub.2multilayer cap/Ge film/SiGe seed layer
[0110] When performing the multilayered cap layer forming step,
n.sub.4 is made larger than n.sub.5 (n.sub.4>n.sub.5) in the
former-half period of the execution period of the multilayered cap
layer forming step, and n.sub.5 is made larger than n.sub.4
(n.sub.5>n.sub.4) in the latter-half period of the execution
period of the multilayered cap layer forming step. That is to say,
when the multilayered cap layer is grown, Ge-rich crystals are
grown in the lower layer portion of the multilayered cap layer (on
the side closer to the Ge film), and Si-rich crystals are grown in
the upper layer portion of the multilayered cap layer (on the side
of the surface).
[0111] Even with this modification, the same effects as those of
the film forming sequence shown in FIG. 4A and those of
modifications 5 and 6 can be obtained. Further, by changing (by
applying gradation to) the composition of the multilayered cap
layer over the thickness direction as described above, the lattice
constant difference between the Ge crystal constituting the surface
of the Ge film and the Si-rich crystal constituting the surface of
the multilayered cap layer can be more properly absorbed in the
multilayered cap layer. As a result, the multilayered cap layer can
be made into an epitaxial layer with smaller internal stresses and
fewer defects, and the function as a protective layer of the
multilayered cap layer can be enhanced.
(Modification 8)
[0112] As in the film forming sequence shown below, at least one of
the SiGe seed layer and the SiGe cap layer may be formed without
using the DS gas. That is to say, the DCS gas may be used not only
as a cleaning gas but also as a Si source.
[0113]
(DCS.fwdarw.MG).times.n.sub.1.fwdarw.MG.fwdarw.(DCS.fwdarw.MG).time-
s.n.sub.4SiGe cap/Ge film/SiGe seed
[0114] Even with this modification, the same effects as those of
the film forming sequence shown in FIG. 4A or those of the
modifications described above can be obtained. Further, it is
possible to simplify the configuration of the gas supply system and
to reduce the cost of substrate process.
(Modification 9)
[0115] In the film formation sequence shown in FIG. 4A or the
modifications described above, when forming various seed layers or
various cap layers, by adjusting at least one of the process
conditions such as the number of execution times of the cycle, the
supply flow rates of the respective process gases, the supply time
periods of the respective process gases, the internal pressure of
the process chamber 201 and the like, the composition of the seed
layer or the cap layer may be changed over the thickness direction
(gradation may be applied to the composition of the seed layer or
the cap layer). As a result, the same effects (the absorption of
lattice constant difference) as those of modifications 4 and 7 can
be obtained.
(Modification 10)
[0116] As the first process gas, as described above, a chlorosilane
precursor gas other than the DCS gas may be used, or a
chlorogermane precursor may be used. Furthermore, as the first
process gas, in addition to these halogen-based precursor gases, it
may be possible to use a halogen-based gas not containing Si or Ge,
such as a hydrogen chloride (HCl) gas, a chlorine (Cl.sub.2) gas, a
boron chloride (BCl.sub.3) gas, a chlorine fluoride (ClF.sub.3) gas
or the like. Even in this modification, the same effects can be
obtained by setting various process conditions similarly to the
process conditions of the film forming sequence shown in FIG.
4A.
(Modification 11)
[0117] As the second process gas, in addition to the
above-described silicon hydride precursor gas, it may be possible
to use an aminosilane precursor gas such as a butylaminosilane
(BAS) gas, a bis-tertiary butyl aminosilane (BTBAS) gas, a
dimethylaminosilane (DMAS) gas, a bis-dimethylaminosilane (BDMAS)
gas, a tris-dimethylaminosilane (3DMAS) gas, a diethylaminosilane
(DEAS) gas, a bis-diethylaminosilane (BDEAS) gas, a
dipropylaminosilane (DPAS) gas, a diisopropylaminosilane (DIPAS)
gas or the like. Even in this modification, the same effects can be
obtained by setting various process conditions similarly to the
process conditions of the film forming sequence shown in FIG.
4A.
(Modification 12)
[0118] As the third process gas and the fourth process gas, in
addition to the above-described germanium hydride precursor gas, it
may be possible to use an aminogermane precursor gas such as a
dimethyl aminogermane (DMAG) gas, a diethyl aminogermane (DEAG)
gas, a bis-dimethyl aminogermane (BDMAG) gas, a bis-diethyl
aminogermane (BDEAG) gas, a tris-dimethyl amino germane (3DMAG) gas
or the like. Even in this modification, the same effects can be
obtained by setting various process conditions similarly to the
process conditions of the film forming sequence shown in FIG.
4A.
Other Embodiments of the Present Disclosure
[0119] The embodiments of the present disclosure have been
specifically described above. However, the present disclosure is
not limited to the above-described embodiments but may be diversely
modified without departing from the spirit of the present
disclosure.
[0120] The recipes used for the substrate process may be
individually prepared according to the process contents and may be
stored in the memory device 121c via an electric communication line
or the external memory device 123. When starting the process, the
CPU 121a may appropriately select a proper recipe from the recipes
stored in the memory device 121c according to the contents of the
substrate process. This configuration enables a single substrate
processing apparatus to form films of different film types,
composition ratios, film qualities and film thicknesses with high
reproducibility. Moreover, it is possible to alleviate the burden
borne by an operator and to quickly start the substrate process
while avoiding any operation errors.
[0121] The recipes mentioned above are not limited to
newly-prepared ones but may be prepared by, for example, modifying
the existing recipes already installed in the substrate processing
apparatus. When modifying the recipes, the modified recipes may be
installed in the substrate processing apparatus via a
telecommunication line or a recording medium storing the recipes.
In addition, the existing recipes already installed in the
substrate processing apparatus may be directly modified by
operating the input/output device 122 of the existing substrate
processing apparatus.
[0122] In the aforementioned embodiments, there has been described
the example in which films are formed using a batch-type substrate
processing apparatus capable of processing a plurality of
substrates at a time. The present disclosure is not limited to the
aforementioned embodiments but may be appropriately applied to,
e.g., a case where films are formed using a single-wafer-type
substrate processing apparatus capable of processing a single
substrate or several substrates at a time. In addition, in the
aforementioned embodiments, there has been described an example in
which films are formed using a substrate processing apparatus
provided with a hot-wall-type processing furnace. The present
disclosure is not limited to the aforementioned embodiments but may
be appropriately applied to a case where films are formed using a
substrate processing apparatus provided with a cold-wall-type
processing furnace.
[0123] In the case of using these substrate processing apparatuses,
film formation may be performed by the sequences and process
conditions similar to those of the embodiments and modifications
described above. Effects similar to those of the embodiments and
modifications described above may be achieved.
[0124] By using the Ge film formed by the methods of the
embodiments and modifications described above as a channel of a
transistor, it is possible to greatly improve the mobility of
electrons in the channel and to greatly enhance the electric
characteristics.
[0125] The above-described embodiments and modifications may be
combined as appropriate. The process conditions at this time may
be, for example, process conditions similar to those of the
above-described embodiments.
[0126] According to the present disclosure in some embodiments, it
is possible to improve a film quality of a film formed on a
substrate.
[0127] While certain embodiments have been described, these
embodiments have been presented by way of example only, and are not
intended to limit the scope of the disclosures. Indeed, the novel
methods and apparatuses described herein may be embodied in a
variety of other forms; furthermore, various omissions,
substitutions and changes in the form of the embodiments described
herein may be made without departing from the spirit of the
disclosures. The accompanying claims and their equivalents are
intended to cover such forms or modifications as would fall within
the scope and spirit of the disclosures.
* * * * *